Generator Engine Running Fast, No Power, Water in the Tank - Can It Be Saved?
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- เผยแพร่เมื่อ 12 ก.ย. 2024
- Picked up this Briggs and Stratton Generator that someone repowered with a Subaru EX30 engine. The listing stated that the engine was running too fast when not under load, but that the engine ran and it made power. Long story short, it did neither and has a long list of problems. Will it run and make power again?
Subaru Engine Model#: EX300D52011
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I am totally blown away on how you could take what looks like junk and turn it into a pot of gold! Well done!
Thanks so much! It could have gone wither way. This one was bad.
I am generally fairly handy , but have very little aptitude about small engines, although I have quite a few for different applications . I find myself addicted to this channel and have watched most of the videos , some twice . I feel they have helped me so much that I would be able to now tackle some basic repairs . I think the channel is amazing !
Great catch on the missing diode!!
If you had to pay some one to repair it would be cheaper to buy a new one... Good to have your skills.
lol the old Mustie1 water in the white coffee cup test. Hands down and without a doubt, your channel has slipped into my number two favorite channel.
Thanks!
I was just thinking, James is the Mustie1 of generators. Awesome video and great troubleshooting.
@@jackmahogovv ditto that for sure. I totally believe James has an amazing amount of talent in the small engine/generator field.
Mustyone would not have transferred the unit to a new frame because of rust . . . he'd mix kerosene and bar/chain oil and spray the rusty piece. Instead of making a proper gasket, he'd have used a liquid gasket maker. If he recognized a heat shield was missing, he'd have said "it ran fine for the owner without it, so leave well enough alone." And he'd NEVER spend $90 for a carburetor if the existing POS clone allowed combustion. And for a spring, he'd make something work. I'd never buy anything renovated by Mustyone; he quotes the good Dr Goodenov way too often.
Mustie1 lol hardly
I've never had to tackle a repair on a generator itself, but by watching you're video's , I think I can do a decent job troubleshooting one of them....Thanks for all you do for us!!!
Ya keep thinking that. He makes it look easy just like Richard at Precision Transmission. I wouldn't suggest ripping apart your 1LE to rebuild it or your generator :)
I ran my riding mower in to my swing set and it hit the springs on the carb that regulate the RPM.. I almost doused it in gas and lit it on fire trying to get it to run right again. I was so pissed and couldn't get it I actually took it back to the dealer and they fixed it. I used to be an aircraft mechanic in the Air Force and generally pride myself with being good at these things... My pride is still scared by that mower.
I appreciate your appreciation of the using the correct torque values.
I have learned so much by watching you repair generators, it's just awesome 👍. Thanks
Found a discarded Dewalt 3100 psi pressure washer with a 6.5 hp genuine Honda engine that was slightly siezed. Freeded it and spun it and it felt smooth. Removed the pump to work on the engine. The pushrods were off their rockers and the lash cap was in the valve area. I thought it had 2 lash caps so I opened the crankcase and found the plastic center of the governor in the cc undamaged. Only 1 lash cap and put the pushrods and rockers in place. Good compression and smooth turning. Carburetor bowl was as rusty as yours so I soaked it in vinegar which removed the rust and left 3 pinholes. I didn't like the looks of the aftermarket carbs ( $8.95 to about $50.00) so I ordered a replacement bowl and rebuild kit for under $20 and a valve cover gasket. Engine has low hours and runs perfectly. Turned the pump by hand and it rotated smoothly. Primed it and installed it on the engine. Connected to a hose , started it watched the pump break.
The pump needed 2 parts both NLA.
Dewalt graciously sells a replacement pump for ONLY $799.00 or about the retail cost of the entire unit in 2007. Bought a new aftermarket pump rated for 120 hrs for $50.00 and a gun with 5 spray nozzles, 50' hose for a grand total of
$ 125 to $130 for everything. Runs
great. First OHV engine I have opened up, very nice engine.
Today I worked on a 38' Cigarette Top Gun with twin Supercharged 502 Chevy's with two Holley double pumper carbs on each engine. These carbs have 4 idle mixture screws , so 8 mixture screws per engine. Fun! Oh and the bilge is a little oily so the pressure washer will come in handy!
I am becoming more and more confident about how to diagnose and repair and maintain small engines. Thank you James. Just bought a feeler gauge and a compression tester. Thanks James its the kind of knowledge we all need to have in a Grid Down or when the Sh*t hits the fan.
Those on/off switches will get you every time. That guy that sold that to you knew what was wrong he just didn't tell. Thanks for sharing your video with us. Ed
Probably, but the price was right. Also came with a generator cord so worst case I had $70 in it for a parts machine.
Nice work.
Another way to make a gasket: a small Toffee hammer and gasket paper material against casting - gently tap around to cut/mark the paper
I was just about to add that comment myself. Not sure what a "toffee" hammer is, but what I've heard called an 8 ounce engineer's ball pein hammer. Using the ball end, and as you said. One advantage of the hammer system is you don't need to "transfer" the pen rubbing paper. The gasket is neatly formed by the gasket material and should come away neatly with almost no trimming needed. One can even form the bolt holes also.
@@KiwiCatherineJemma I have a small ball pein hammer that I've had for over 50 years and that's all I've ever used it for. In most cases it's worked great. I'll have to say James crayon made a great ''impression''
James that ended up being a nice generator. I learn more every time i watch a video of yours. Ive worked on all kinds of engines but have never worked on a generator because of the power head. I was surprised the Mr.Funnel didnt work. Steves Small Engine Saloon recently did a video on that funnel and poured in a full bottle of water and it didn't leak a drop. 🇺🇸👍 Roger
Maybe my funnel is defective. Not sure, but it definitely did not do what I thought it would
.
Nice job on restoring/remanufacturing that generator. I've watched almost all of your generator videos and I can't remember you finding and correcting so many problems on one generator before.
The Generac 10000EXL, the Ridgid with the stuck engine and the Chinese Inverter generator where probably worse. But this one ranks up there.
I love your calm and completely logical approach to diagnosis. And utterly patient...the word Zen keeps coming to mind. The explanations are just excellent. You have the heart of a teacher. Your hands are perfectly efficient, a real joy to watch. Many people showing repair on TH-cam have no business inside a machine of any kind. You are the thorough exception. I'm guessing this is your "second job" done evenings because it seems you're frequently finishing up late at night. I wonder (if I'm guessing correctly) what your day job is. Maybe brain surgeon. :)
Most work is done at night when the kids are sleeping. Otherwise it would be constant interruption. And yes, this is a "second job". The day job involves large computer systems.
@@jcondon1 Nice. Mine, too. :)
@@jcondon1 f
Nice work on showing how you can tell if the governor is intact @17:00
You took a very rough machine and made a gem . Good Stuff
I worked on ground equipment (Generators, heaters, test stands etc) in the USAF for 15 years. You are very thorough with your repairs. Very impressive.
Thank you!
Well done, as usual, James.
I have been following for some years and have seen the transition in confidence from halting to full blown knowledge and experience. The change is welcome and for the better.
I used to repair and maintain small engines on mowers and generators, etc until needed hip replacement sidelined me.
Good to see another taking up the cause. I learned a lot about generators from your channel and follow just due to interest and entertainment. Fun channel and educational.
Thanks for sharing.
Dr. James Generator!
Good work as usual and thanks for the tutorial on adjusting the governor. Love the Teflon trick and the 1" coupler extension for the motor mount. When discovering rust on a crankshaft taper, one is tempted to lube it when reassembling but that is a no-no. Oil or grease will make it more difficult to separate next time because of a good seal between metal surfaces. Gaskets can be much more easily made by punching the two mounting holes, installing two temporary bolts and then using a very small hammer to tap on the gasket material to leave an impression.
There is no Olympic competition for "Jumping to Conclusions" and I have stop practicing for that event a long time ago. :-)
BTW from what I know, they are not called "ropes" on the windings but rather "lacing". It appears Santa may have been good to you with a set of gear wrenches which I just love.
Keep the GREAT videos coming.
Really like the in depth video, between you and Mike aka S.E.M. I feel as though I'm back in school. It's a mystery as to why these videos interest me so much but they sure do and I really thank you for taking up your time to produce them.
Glad you enjoyed it! Mike makes some good videos.
2 new motor mounts...50 bucks plus the new carb and I believe it was 75...not to mention your time and shop supplies and other components missing...not much of a profit. Probably had 200 or so in it.
Your videos inspire me to do the same...great attitude and always work through the issues...great job Mr. Condon
The seller knew that it wasn't making power, and that it wouldn't start. He just wanted to get someone out to look at it, and sell it.
$225 initial cost and parts (not including labor), not much room for profit. Generator looks and runs great.
yeah idk how he makes any money, everything has to be perfect and brand new, the parts cannon gets fired a bit too often for my taste
Knowledge is power.... And savings!
The amount of money we throw away because we don't know how to diagnose and fix things is unbelievable. I started watching these videos because I saw you worked on a generator that I have, now I'm just watching all of them. I like to see you find The problem and fix it. That's the entertainment value for me anyway.
Thanks
Sometimes stopping and having a good THINK on it, or doing a bit more research can save you for making a hasty declaration. When you have a greater amount of success than fail, it's a good feeling.
I'd of been looking for that missing diode down in the head area, hate to have that get waded up while spinning. I have to laugh at myself, watching so many of your videos I now want to have my own generator around the house. It's funny because I live 2 blocks from a substation and have lost power 2 times in living here for 38 years. Guys want their Motors :)
Excellent video but $100 is way too much to pay. Free would have been more realistic.
Free or scrap metal pricing if a person could use the machine for parts.
Kijiji mint
I've learned so so much watching your videos and yet i probably seen a fraction of them. On with the rest of them, thanks James.
Never take someone's word if it works or not. Always try to run the product before making the purchase, I have watched most of your videos and love them! $100 for that in my area is a good deal though, with a $400 resell in a few days. The description is completely misleading and you could have talked them down more if you tried.
I could have talked him down. Felt bad though. He clearly needed the money. It also came with a 30 amp generator cord. So when you factor that in, the price was more like $70.
@@jcondon1 very commendable. love watching your videos, keep it up and keep the coming!!!
James - I enjoy all the video's , think I learn something from every video - thanks ...
Glad to hear it
You need a Taryl Fixes All white coffee mug for these engines with poor gas
Wow that was a lot of diagnosis and fixing. Fabulous job on the entire video. Should be a good generator for new buyer. Thanks for the video and all the testing.
Brilliant as always James yes the small engine mechanic is a great channel also stay safe 🇦🇺👍
James, you're the best, your videos are well put together and properly edited to cover what really matters and educates that is relevant to the lesson/session, unlike so many others out here. Keep up the great work buddy. One tiny little bitty piece of advice to you, stop calling nuts bolts, not kool.
I know. Seems to be a mental block. Never notice until editing the video.
I laughed out loud (aka LOL) when you opened the old float bowl. "There probably is an issue."
Wow! Talk about coming in behind someone else's work. I literally lol'd when you opened up the original carb. I said "nice!" about 1 second before you did when you ran it with the new brushes and it made power. Super lucky catch watching the small engine mechanic channel and seeing a black winding there! Educational for us now too and classy to give credit where credit is due. Swapping to the new frame dressed it up nicely and adding the governor spring and adjustment clearly resolved the original "low idle" issue. Hate that you had to put $90 into another carb, but at least you know it runs right and won't likely be back. Excellent work, video and editing as always! 👍👍
That carb cost about as much as the whole machine. Of coarse the carb went on sale for $75 after I paid $90.
@@jcondon1 Yeah I noticed the screenshot that you showed in the video was $75 instead of $90. I've never had a piece of flipped equipment come back so there is definitely merit in doing it right the first time. I figure you should make $150-$250 off of it depending on demand so still a profit. Labor of love (or learning) time doesn't count imo. If you enjoy it then it's not "work" imo. Insert adage here.
James, love your integrity and knowledge. Always fun to see the videos. If you're willing to share the info, it would be really interesting to see the financial gains or losses as you sell these machines. Nice work!
Have thought about it. This one cost $100. It came with a $30 generator cord so $70 for the generator. $90 carb, $9 governor spring and $17 air filter. Close to $200 into it. If you factor in labor, then I lost money. Otherwise I made about $150 on it. The new carburetor cost more then the whole machine. That is why clone carbs are so popular.
@@jcondon1 I like that idea of doing a breakdown list of parts costs. Sales price would be good also but that is a personal decision.
You did a fantastic repair job. You really know these engines. Good job. Thanks for sharing
Nice idea using the 1 inch threaded nut to extend the hight for the isolators for the power head
That turned out very nice! Someone sure went through a lot of effort before you but came up short, then they added to the trouble by leaving it outside. I’m surprised that engine didn’t have a rod knock considering the governor was completely out of the picture. Another great save!
Subaru engines are built well. Never had one that did not work. I was expecting rod knock or at least glitter in the oil. Fortunately it had neither. There was a lot a sludge though. Changed the oil several times to try and get it a little better in the block.
James, great work as always. BTW, I received the Kill-A-Watt from your viewer giveaway and it works great! So nice to have a tester to check and set the speed correctly. I have seen on the Mustie1 and Machinery Restorer channels a small lift to work on riding lawn mowers. I think that would do good things for your knees and back. Have you looked into getting a referral program from some of your vendors? I know I would gladly use the the links when I need a part. All the best for you and your family in the New Year and keep the great videos coming.
That "black varnish" is typically an epoxy paint layer applied to the stator to give it better moisture resistance. Leroy Somers has a whole bunch of different levels of winding protection, this is their basic upgrade. Serious outdoor stuff will get DVPI epoxy insulation with the paint on the stator and rotor. That stuff looks completely different. You'll sometimes see it on bigger alternator heads.
Never seen it before on one of these generators. Now I know...
It's easy to fix things, when you know what you're doing.
Good job sir. Thank you. The governor portion was very helpful for me.
James, Good useful content. Have repaired a few generator basket cases myself. I see a lift table in your future as my aging back and knees are hurting watching you. Wish I had more room to store spare parts which often make some project viable. Regards, T
That was a great save and clean up Jim! Awesome job. You know something, you can’t get the muffler for these anymore. No one has them and are discontinued. That’s a bummer, because my EX30 needs one 🙁
I've never seen that rope trick, pure genius. I'll have to try that on my motorcycle 🏍.
Well done, good job! Youve got a good eye for small details I probably wouldve missed!
hi james good to see all that hard work payed off ,new carb made it work very well
It is amazing what a close to OEM carb will do.
Great work. But I personally would have cleaned the rust on engine shaft even it does not affect the working in the short run. Also, painting the rusty screws could have been the little perfect touch.
My old governor adage is, adjust the gov/throttle. If you can't move the linkage, when you're done,...it's adjusted backwards. Do it over with linkage adjusted the opposite way, so you can move it when you finish...
That works
"But wait, there's more!!!" with every new discovery... LOL
your vid helped alot with a flooded carb. replace carb and it started up! thanks!
125.00 means he wants 100.00 .
offer 75.00 and settle at 80.00 , now you're negotiation .
you're very mechanically incline and very good at explaining procedures 👍👍
Thanks. Got him to throw in that extra carb and a $30-$40 generator cord so in the end it was closer to $70 for the generator.
Thanks for the video! I got a generator from Facebook Marketplace with the springs for the governor messed up. This helped me a lot!
Great video yet again. I've had a few that the copper looked olive drab color. Thought for sure the stater was cooked. They tested well and produced well. I'm glad to find out that is done on purpose but I still prefer the shiny copper look. Lol
Great information. I think I can tackle my own . The engine runs but no power output.
Another great job...when are you to get an air lift table for your shop? Work smarter, not harder all good my man, peace.
You are a great teacher given your diagnosis as you go. That experience come over time . Thanks for sharing greetings from DUBLIN IRELAND
Thanks and cheers! I work with a few from Galway.
@@jcondon1 give then my regards (city of tribes) Irish.(Cathair na dTreabh.
Named after the local type of boat, not the rugby player, nor any other hooker you might be thinking about. Aka the Gaeltacht County,
great work I did not think you could rescue this one.
This one was rough
Another great video!
I worked in an a couple of electric motor shops winding coils for rewinding motors when I was in school, about 50 years ago so this may be out of date. The wire we used most of the time was Formvar insulation and it looked like the gold color wire you see most of the time. One of the shops also wound hermetic compressors and it used a class F insulation wire that could stand higher temperature operation. This wire was often much darker due to the different type of insulation when it was manufactured. I also remember the wire color changing with different manufacturers even when it had the same specification. I would suggest that you base winding condition on the smell and texture of the wire. Like you mentioned if the tie wrapping is in good condition the winding probably has not been too hot.
Have you ever compared the main jet size in a clone carb with the OEM one. I wonder if the clone would work better after changing out the main jet. It might provide a cheaper option that buying OEM replacement parts.
Thanks. These mostly use class F insulation. Don't think much has changed. A agree on the smell test. The eyes and nose will tell a lot about the condition. I bet an adjustable jet would cure the clone issue.
Nice find on the power head being good
Asides from a poor optic. From the structural engineering viewpoint, because of the limited supporting area between your improvided (rubber foot) extension and the intended target areas, premature material fatigue could be an unnecessary issue.
Other than that your channel is among the best on earth.
Thanks for sharing your knowledge and your contiguous enthusiasm.
Your troubleshooting expertise makes for really interesting videos. Thanks for producing them.
I'm only asking because I don't know, but isn't it possible to re-jet a carb that's running rich? Jets are much cheaper than carbs!
It is possible, but not sure where to source the jets for a mikuni clone or a Mikuni for that matter.
You can lean out a rich running carb by fastening a piece of copper wire through the main jet. Make sure it is tight against the side of the orifice as the area is different if it is centered or tight against the side. Obviously you have to experiment with the wire diameter. Copper wire can be hammered and or filed to modify the size. Alternatively measure the existing jet size with a miniature (60 to 80) drill set and solder or epoxy the jet closed and redrill it smaller. The wire allows you to experiment without making a permanent change. I LIKE the old fashioned adjustable jets.
Awesome what you are capable of doing and your knowledge of generators is simply amazing!! Fastest hour vid I’ve seen in some time! Kinda wish work would by that fast! lol 👍🏻
Thanks 👍
James...all of us subscribers should pitch in and buy you a jack table for you to work on equipment. Pains me to see you stoop down and work on the generators and such. You up for it, James?
I would never turn down the gift of a tool. That said, the back and knees are good. Pinched a nerve real bad though a few weeks ago by sleeping in the wrong position. Took almost two weeks to get back to normal.
that muffler fluffed out nice! I like the high temp ceramic paint.
Nice job on the home made gasket. Faster and cheaper, which is how we roll. Picasso, eat your heart out.
Nice job: I can't believe what some people do to engines and equipment. I also get some strange things in my shop that people did crazy things to. Thanks for great video's.
A lot of these I pickup are because someone do not want to bring them to a shop and end up making a minor problem much worse. I picked up on for free that tank vent line came off the air box. He plugged it back in to the wrong place, cutting off the tank vent. In his troubleshooting me messed with the governor and idle screw making if far worse. Ended up costing nothing to fix that one.
@@jcondon1 Great job, thanks
Nice find a Subaru swap wow @James Condon
First time I've seen an outlet panel with that little illumination LED.
Wow at all the water
Thats a good idea to support the gen head with those long nuts.nice work man.
Great Job James and another great video. I too had my doubts but as usual you prove me wrong lol. It would have looked even nicer with that red tank on it that you had in the background but were do you draw the line.
I did not fit :(
That stens carb is super nice
Doc, great job and a great learning experience for me.
Glad to hear it!
You need a small single handle meter and variable load bank with light, just have 10 1000 watt heat coils and a large fan and a switch for each coil, then 4 250 watt heat coils and 1 on a dimmer or something to adjust it, then have the killawatt plug right in and have a light on the side/front panel (depending on if you call the vents the sides or the front and back)
A load bank would be great! But to choose between a $20 space heater and a $3,000 load bank is an easy decision. This is just a hobby for me. Maybe someone has an extra load bank they want to donate??
@@jcondon1 I meant make one lol
@@aterack833 that could be a fun project.
Easy? A one axle wheeled table (3' x 2') with bottom shelf, where the heaters are mounted, slide-in handles; switchable power boards; a plywood panel for the testers and a swing out camera mount. Less bending for James. Call it The James Condon Power Barrow. Like the Greg Judy Roller (my other TH-cam addiction).
Simple fix for the power head the bridge rectifier wasn't complete
Did it again ! Lots of parts needed on this one I hope you made something on it. Nice looking frame, great sounding engine with new carb., Polished up slip rings and new brushes. All torqued in there nice and even. Spaced up level. I wanted to see you paint that nasty looking foot so bad. LOL Hey, we are all human so I will get over it, Right? I shouldn't complain because I have done "a lot" worse. Love these videos so don't take me serious. Very nice work my friend.
Nice job mate. I've learned a lot from your detailed, informative and interesting videos. Keep up the good work. 👍
Thanks 👍
great job james looks like a good generator now
That does look like a wire clothing hanger very nice try on the home made governors rod
I have one of those funnels if you notice the Recess in the bottom. I think it’s all designed for a small amount of water . And the idea is that the water should go to the bottom of the funnel underneath the filter. Well if you have a large amount of water in your poured it in there it’s just gonna go right through that filterl as you found
Great work James 😊
I realize it is not really our business to know but it would be truly interesting to see a few “final accounting” for some projects, especially the more challenging ones. Of course the TH-cam channel provides financial benefits and that is not our concern but the actual project accounting would be interesting. Clearly postage etc is a problem, especially for small stuff like gaskets and springs. Anyhow, just thought I would ask. Really good project with a lot to solve. The missing diode was a new one! A full bridge certainly won’t work on three diodes!
In total I spent about $200 for the generator including the parts to fix.
Generator $(100.00)
Generator Cord $20.00
Carburetor $(90.00)
Oil $(8.00)
Governor Spring $(9.00)
Air Filter $(17.00)
@@jcondon1 very interesting. Thank you James. I not only enjoy your channel and style but learn a lot too.
Great job on your videos. Makes me wish you would get one of my old engines so I can find out what the hell I did wrong. :)
Great job and always a pleasure to watch
Two thumbs up for your excellent videos!
I think your ethics on this genset are greater than mine. I would never have bought a close to oem carb for 90 dollars after giving 100 dollars for this thing in the first place. In our area you would be very lucky to get 250 for this genset. In your storm prone area you might get 400 for this overrevved genset thus slightly covering your loses but I would have gotten the rich running to normal thus saving the 90 for a tiny profit. The person who gets this genset had better not rely on it not failing in its first hour of use.
It is easy to get a lean carb to run rich, but how do you get a rich carb to run lean? Have not yet had a blown Subaru, but I agree, this one has had a hard life and would be more likely to fail.
Well done, Mr. Condon!
I think you should have just given him to $20 that he originally wanted! Also, back in the 20-30's, aviators would filter their gasoline to remove any absorbed water, by using a funnel that was lined with a natural Chamois leather for a filter. The Chamois is moistened first and squeezed out before use.
This one was a real doozy. The list of things that were bad seemed to be bigger than what worked good and right
Your parts guy must really like you
***A 3D PEN*** can repair ABS plastic splits & breaks, plus restore any stripped/worn bolt holes & rebuild snapped-off lugs. Coat your bolt in non-oil lubricant (eg talc) sit it in the worn out hole, use the 3D pen to "inject" black molten ABS all around it then let it cool+harden & you're good to go.
The only people who would have noticed the color mismatch between the frame and engine are you and other people who work on generators for a living. lol! Great job as usual. I can't help but wonder if that diode was missing because someone thought it would fix a perceived problem. That whole thing with all those problems comes across like a failed Frankenstein experiment by someone less experienced than you or a pro. When you first pointed out the dark windings, I thought 'but none of the strings we see are burnt/broken'. If most gen heads are made in China, maybe the darker varnish is just Chinese 'quality control'. As long as the gen head works, the color of the varnish is probably not relevant, just confusing since the color can be part of the diagnosis process. Keep up the great work!
Funny you should mention that. When selling it, someone said that had the exact same generator. The voice in my head was saying, unlikely.
James ist good 2 see big job we like whach more diffucult one Not a easy one so hope we get whach fix jenerator more diffuculd and big job thanks 👍
Wish I could always find ones like this. Someone offered me a working generator. I said, "I only buy broken ones". Think I confused him. That said, bought a broken one recently. Turned out the spark plug was not connected properly to the wire. Sometimes they are easy.
@@jcondon1 u do great job 👍 we love 2 whatching thanks james
Wow fired right up
Defenitly looks way nicer on the husky frame
I've made gaskets a long time, all you need is a small ball peen hammer and a exacto knife. I do it right on what ever I'm making it for. I'm not saying the way you do it is wrong. I'm old school.